Process for creating pellet for utilization in land revegetation or as a fuel source

ABSTRACT

A process for revegatating land includes the steps of performing a soil analysis, creating seed-bearing pellets according to soil needs, and disbursing the seed-bearing pellets over the land to be revegatated. Such seed-bearing pellets are created by mixing nutrients and ground organic material. The mixture is saturated with steam and pressed through a die and cut into individual pellets. Seeds are adhered onto each pellet, and activated charcoal may be fixed to the outer surface of the pellet to neutralize herbicide applied to the land to be revegatated. A process for creating fuel pellets is also provided which includes grinding and mixing waste wood products, and adding oil to the mixture. This mixture is injected with steam and pressed through a die. The pressed mixture is then cut into cloverleaf configured pellets.

RELATED APPLICATION

[0001] This application claims priority from provisional applicationSerial No. 60/216,719, filed Jul. 7, 2000.

BACKGROUND OF THE INVENTION

[0002] This invention relates generally to outdoor cooking fuel and landreforestation and rehabilitation. More particularly, the presentinvention relates to a process for creating pellets which can beutilized as a fuel source, or facilitate land revegetation.

[0003] Outdoor cooking charcoal briquets have been commerciallyavailable since the 1920's. Such briquets are made from a combination ofsemi-anthracite coal, sodium nitrate, limestone, borax, and variouspetroleum-based binders. Such briquets are difficult to ignite, usuallyrequiring more than two attempts with lighter fluid and matches.Approximately 30 to 50 briquets are placed in a mound during eachoutdoor cooking event. After lighting the briquets, there is typically a20 minute wait before being able to cook the food. This wait is requiredin order for the toxins and the objectionable flavor that the anthracitecoal, sodium nitrate, limestone, borax and various petroleum-basedbinders produce to be burned off. Since the charcoal briquets have atotal burn life of approximately 40 to 50 minutes, only 20 to 30 minutesof cooking time are left. Even after waiting, many consumers complainthat the briquets impart an objectionable petroleum taste to the food.Recently, briquets have been provided which require no waiting afterigniting with a match before cooking. Cooking time is thus extended to40 to 50 minutes. However, many consumers have complained about anobjectionable petroleum taste imparted to the food throughout the 40 to50 minute burn time of the charcoal briquets. All charcoal briquets arecomposed of carbon black and cause the users' hands to become dirty.Another disadvantage of the charcoal briquets is that the process ofmanufacturing them produces large amounts of black smoke filled withparticulate matter known to cause respitory problems in humans.

[0004] Presently, nutshells, sawdust, and the remains and dead andinfected woods are often disposed in landfills. Current means ofgenerating energy often include the burning of oil, natural gas, andcoal. All of these methods release a tremendous amount of environmentalpollutants in to the atmosphere. There is an increasing movement towardsthe use of “green” energy resources which recycle materials and produceenergy with little or no harmful byproducts.

[0005] There exists in many areas of the world, foreign or noxiousplants which create obstacles to productive native plant life either byrobbing nutrients, moisture, sunlight or space or by creating a firehazard. The U.S. Forest Services is currently engaged in the practice ofperforming “controlled burns” in a process to improve forest andgrassland habitat. Many times, these “controlled burns” become“uncontrollable wildfires” which cause great damage to humans, animalsand plants. Proponents of the controlled burns state that such “burns”are necessary to lessen the likelihood of “wildfire spreading” and that“controlled burn” fires create the high temperatures and smoke residuesfor germination and growth of certain native grasses and plants.However, there is the constant risk that controlled fires can becomeuncontrolled fires in a matter of seconds because of abrupt weatherchanges. Thus, such burns can actually create more damage than theintended benefit. Herbicides have been used sparingly as the herbicidetypically kills all plants which come in contact with the herbicide.This creates a concern for erosion as it often takes quite some timebefore the effects of the herbicide diminish sufficiently to allow newplants to grow.

[0006] Accordingly there has been a need for a fuel pellet or briquetwhich is clean, provides high energy output, and burns long enough toprovide 40-50 minutes of cooking time. Additionally, a briquette isneeded which can be used to flame broil, barbecue, bake, and smoke orcure food which can be used on a gas or electric grill depending on theneed of the outdoor cooking consumer. Such a briquet pellet shouldimprove the flavor of the food and be capable of being manufacturedeconomically.

[0007] What is also needed is a fuel source which recycles wastematerial and emits relatively little environmental pollutants. What isfurther needed is a process for reforesting and rehabilitating grasslands. The present invention fulfills these needs and provides otherrelated advantages.

SUMMARY OF THE INVENTION

[0008] The present invention resides in a process for creating pelletswhich can be utilized as a fuel source or in land revegetation. The fuelpellet is created by grinding and mixing waste wood products, such asnut shells and hardwoods. Oil, such as canola oil, is added to theground waste wood products mixture. Steam is injected into the mixtureand the mixture is densified by pressing it through a die. The mixtureexiting the die has a density of between 50 and 90 lbs. per cubic foot.The pressed mixture is cut into pellets, typically into a cloverleafconfiguration, and allowed to cool. The cooled pellets may then beshowered with additional oil if deemed necessary.

[0009] The resulting fuel pellet can be used to flame broil, barbecue,bake, and smoke or cure food. The use of nutshells and hardwood impartsa desirable flavor to the food, and allows for an appropriate cookingtime.

[0010] The process for revegatating land, such as areas that have becomeovergrown with non-native plants, includes the steps of first performinga soil analysis on the land to be revegatated. Seed-bearing pelletshaving nutrient enriched ground organic material are created accordingto the soil needs of the soil analysis. These seed-bearing pellets arethen disbursed over the land to be revegatated.

[0011] The pellet is created by providing a mixture of nutrients andground organic material. This mixture is saturated with steam anddensified by pressing the mixture through a die to create a pellethaving a density of between 50 and 90 lbs. per cubic foot. After cuttingthe pellets into the appropriate size, one or more seeds are adheredonto each pellet. Preferably, the ground organic material includesground almond shell which serves as a chelator and ground alfalfa whichfacilitates water absorption. Depending upon the needs of the soilanalysis, mycorrihizal innoculum is added to an outer surface of thepellet to assist the plant in obtaining the proper nutrients from thesoil. An ingestion repellant may also be added to the pellet todiscourage insects and animals from eating the pellet.

[0012] In the process of reforesting and rehabilitating land, theunwanted trees or vegetation on the land to be revegatated arepreferably destroyed. This can be done by applying an herbicide to theland to be revegatated. In this case, activated charcoal is attached toan outer surface of the pellet which serves to neutralize the herbicideand allow the seed to grow.

[0013] Other features and advantages of the present invention willbecome apparent from the following more detailed description, taken inconjunction with the accompanying drawings which illustrate, by way ofexample, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The accompanying drawings illustrate the invention. In suchdrawings:

[0015]FIG. 1 is a flowchart illustrating the steps taken in creating afuel pellet in accordance with the present invention;

[0016]FIG. 2 is a flowchart illustrating the steps generally taken inrevegatating and rehabilitating land in accordance with the presentinvention;

[0017]FIG. 3 is a flowchart illustrating the steps taken in creating amulch/seed pellet used in the process of revegatating land.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] As shown in the drawings for purposes of illustration, thepresent invention is concerned with a process for creating a pelletwhich can be adapted to be used as a fuel source, or bear seeds and beused in land revegetation and rehabilitation.

[0019] With reference to FIG. 1, a flowchart is shown generallyillustrating the steps in creating a pellet or briquet that can be usedas a fuel source. The pellet is comprised of 100% natural products. Itis a combination of nutshells and hardwood residues which are obtainedfrom nutshellers and lumber mills. In the past, these waste materialshave been disposed of in landfills and have created an environmentalproblem. Utilizing these waste materials in the manufacturing of thepresent invention eliminates this waste problem. In addition, themanufacturing process is clean. The nutshells and/or hardwoods areground down to 0.125 inch or smaller particle size and mixed (10). Themixture is not less than 0.005% nor greater than 99.0% by volumehardwood species. The moisture content of the mixture ranges from bonedry to 60%. The nutshell species used can include almond, walnut, pecan,filbert, or any other similar nutshell. The hardwood species used, butare not limited to, oak, maple, alder, hickory, mesquite, fruitwoods andgrapevines. Softwood species may also be used in a limited extent,particularly when the pellet or briquet is to be used in a power plantas fuel, and includes, but is not limited to, pine, fur, cedar, andredwood.

[0020] The mixture is then combined with oil (12). Preferably, the oilcomprises canola oil in an amount of 0.005% to 10.0% by volume. Thiscombination is then thoroughly mixed until the oil is distributed evenlythroughout the mixture of nutshells and hardwoods. At this point, steamis injected into the mixture in quantities of not less than 0.06255% norgreater than 10% of the total volume (14).

[0021] The mixture is then densified by pressing it through a die (16).The die is between is 12″ and 98″ in diameter, and has between 8 and 500individual die cylinders. Each individual die cylinder is designed witha 1.875″ to 4.0″ inside diameter by 1.250″ to 4.50″ outside diameter.The die is constructed of a high heat resistant steel alloy toaccommodate between 20,000 and 50,000 PSI, and between 2000° F. to 1000°F. temperatures. As the die revolves either clockwise or in acounter-clockwise direction, new material is fed into the die openingand the materials is pressed by a steel roller into the opening.

[0022] The combination of the flow characteristics of the raw material,steam, pressure of the roller, shape of the die and the centrifugalforce of the spinning die at 260 revolutions per minute, causes thematerial to increase in temperature and densify. The extruded materialhas a density of between 50 and 90 lbs. per cubic foot, and preferably adensity of 70 lbs. per cubic foot. Approximately 3 to 5 tons per hourcan be extruded through the die.

[0023] The extruded and densified material is cut into pellets (18) andallowed to cool, causing further hardening of the pellet. A uniquefeature of the die is that it forms the material into a clover leafconfiguration designed to produce a product which has a greater surfaceto air ratio than any other shape that can be effectively extruded. Thegreater surface to air ratio is necessary to maximize combustion due toincreased surface area which comes into contact with oxygen. This moreeffective combustion is a marked improvement over past attempts todensify waste wood products and then burn them. Nutshells and sawdust orshavings have a high BTU content, and therefore are desirable as fuel,but their lightweight causes the shell or sawdust to fly beyond theflame. Also, their inconsistent moisture content causes the product tosmoke excessively, causing air pollution. The excessive smoke can alsobe a flavoring problem when outdoor grilling or barbequing.

[0024] The extruded pellets are between 1.250″ and 4.0″ in diameter andcan be cut at any length, typically between 0.5″ and 14″ long. The highdensity of the product allows it to be stored for long periods of timewithout degradation. The density also yields a product having between8300 and 10,000 BTU per pound. This high BTU content combined with agreater surface to air ratio produced by the clover leaf shape allowsfor a flavorful, high BTU fire with a one hour burn time. The one hourburn time has been found necessary to provide adequate heat for outdoorbarbequing or grilling. The resulting pellet burns cleaner, longer, andgives better flavor to food than charcoal briquets.

[0025] Approximately 200 pellet briquets can be fit into a 10 lb. bag toprovide a consumer with five outdoor barbeques per bag. Due to thegreater surface to air ratio provided by the clover leaf shape of thebriquet pellet, the invention begins to burn immediately with a flame sothat flame broiling food to seal in the flavor as soon possible withoutwaiting. In addition, the briquet pellet can be used in a “smoker” tosmoke and cure food by simply adding 3 or 4 pellets at a time to a gasor electric grill by placing a few pellets near the heat source to addflavor to the food. The pellets are clean, eliminating the need for theuser to constantly wash his hands when working with food. Also, thebriquets are bacteria and germ free due to the high temperatures andpressures during manufacturing.

[0026] The resulting pellets or briquets can also be used as analternative fuel source which is “green” as the materials are 100%natural, and most likely would have been deposited in a landfill.

[0027] Referring now to FIG.2, another embodiment of the presentinvention is illustrated. This embodiment involves a process forrevegatating or rehabilitating land, or reforesting overgrown forests. Asoil analysis is first performed on the land to be reforested,rehabilitated and revegatated (20). The unwanted trees and vegetationare destroyed (22). This can be following a natural forest fire, byremoving dangerous tree and plant species with a hydraulic sheer andchipper, by herbicide or by other traditional means. When removingunwanted tree species, these can be chipped and used in creating thepellets, or act as fuel source for power generation for producing theheated steam in the pellet manufacturing process. Seed-bearing pelletsare then created (24) and dispersed onto the land to be reforested orrehabilitated (26).

[0028] With reference to FIG. 3, the process for creating theseed-bearing pellets will now be described. Organic material is groundand nutrients added to create a nutrient enriched mulch (28).Preferably, the composition of this mixture is determined by thepreviously performed soil analysis which indicates the needs of the soilin order to support the plants or trees to be propagated. Exemplaryorganic material includes cattle or horse manure, soy bean meal, urbangreen waste such as grass and shrub clippings, diatomaceous earth, otherappropriate organic materials. It has been found that alfalfa is asource of protein and serves to absorb surrounding moisture into thepellet. Thus, alfalfa meal is nearly always included in the mixture.Another preferred ingredient in the mixture is ground almond shells. Ithas been found that almond shells act as a chelator which pulls zinc andother heavy metals into the plant root. It is believed that the almondshell does this by forming a chemical compound in which a central atomand a neighboring atom form a ring structure that facilitates the flowof the metal ion into the root. Many nutrients that would be lost tograsses, herbs and shrubs can now be directed towards the plant rootsdue to the chelator effect. Other nutrients, such as nitrogen, zinc,ammonium nitrate, potash, methylene urea, potassium sulfate, ammoniumphosphate, potassium nitrate, urea, and other organic and inorganicnutrients are provided as deemed necessary by the soil analysis.

[0029] After grinding the mixture to 0.175″ or less particle size andcompletely mixing the ingredients of the mixture, the mixture issaturated with steam (30) having a temperature or 212° F. to 700° F.,and preferably 300° F. The steam is injected into the mixture in aquantities of not less than 0.06255% nor greater than 10% of the totalvolume.

[0030] At this point, the mixture of green waste and nutrients is readyto be pressed through a die in order to be densified (32). The mixtureis pressed through a die, preferably 0.250″ in diameter, having a lengthof three to six inches. The temperatures inside the die is typicallybetween 320° F. to 350° F. due to the super-heated steam and thefriction of the material as it passes through the die. Due to theabsence of oxygen within the die, the organic material does not burn butrather melts and densifies. A density of between 50 and 90 lbs. percubic foot is attained, with a preferred density of 70 lbs. per cubicfoot or more. This density has been found to enable the pellets to bestored indefinitely without fear of crumbling or deterioration as withother pressed products. The emerging product is cut into pellets (34)approximately 0.25″ to 0.75″ in length. The pellets are then passedthrough a cooler at 32° F.

[0031] A natural water soluble adhesive is then applied to an outersurface of the pellet, such as by a mechanical rotary mixer, and seed ismetered into the pellet/adhesive mix in varieties and quantitiesaccording to planting and growth requirements (36). The “seeded” pelletsare then dried. If the soil analysis indicates, mycorrihizal innoculumis attached to an outer surface of the pellet (38). This innoculum isknown to have a synergistic effect with the plant by receiving chemicalsignals from the plant as instructions to search out various nutrientsand the like which the plant needs. The relationship is symbiotic inthat the plant roots provide the necessary nutrients, etc., for themycorrihizal life forms.

[0032] When herbicide is used to destroy the unwanted trees andvegetation on the land to be revegatated, the pellets are coated withactivated charcoal (40). The activated charcoal serves to neutralize theherbicide and allow the seed to germinate and grow unmolested. However,herbicide can remain effective for some time outside of the pellet areaand prevent the growth of unwanted plant varieties which wouldimmediately compete with the intended plants. This herbicide/activatedcharcoal pellet process enables the destruction of unwanted plants andtrees without the risk of creating unwieldy forest fires due touncontrolled burns. The process is also economical and relatively easyto perform.

[0033] After the seed-bearing pellets are created and disbursed on theland to be rehabilitated, the contents of the pellets, particularly thealfalfa meal, absorbs moisture resulting in the increase in size of thepellet, and the pellet begins to partially disintegrate. This creates anincubator for seed germination and healthy plant growth. To preventanimals and insects from eating the seeds and pellets, an ingestionrepellant such as habanero pepper, can be attached to the outer surfaceof the pellet (42).

[0034] The pellets are fairly compact and easy to store with anunlimited shelf life. As invasive foreign species encroach upon nativespecies and destroy the beneficial grasses, herbs, and shrubs, thepellets can be used to mitigate this invasion and restore the naturalhabitat. The pellets can be broadcast and disbursed by hand, or aeriallyusing an helicopter or airplane. The result is a more balanced andhealthy ecosystem more resistant to fire and capable of tolerating awell-managed grazing program.

[0035] Although several embodiments have been described in detail forpurpose of illustration, various modifications may be made withoutdeparting from the scope and spirit of the invention. Accordingly, theinvention is not to be limited, except as by the appended claims.

What is claimed is:
 1. A process for creating fuel pellets, comprisingthe steps of: grinding and mixing waste wood products; adding oil to theground waste wood products mixture; injecting steam into the groundwaste wood products and oil mixture; densifying the mixture by pressingthe mixture through a die; and cutting the pressed mixture exiting thedie into pellets and allowing the pellets to cool.
 2. The process ofclaim 1, wherein the waste wood products comprise nut shells and wastehardwoods.
 3. The process of claim 1, wherein the oil comprises canolaoil.
 4. The process of claim 1, wherein the mixture is pressed throughthe die to create pellets having a density of between fifty and ninetypounds per cubic foot.
 5. The process of claim 1, wherein the pelletsare cut into a clover leaf configuration.
 6. The process of claim 1,including the step of showering the cooled pellets with oil.
 7. Aprocess for creating a mulch/seed pellet, comprising the steps of:providing a mixture of nutrient enriched ground organic material;saturating the mixture with steam; densifying the mixture; cutting thedensified mixture into pellets; and adhering a seed onto each pellet. 8.The process of claim 7, including the step of performing a soil analysisto determine the composition of the nutrient enriched organic material.9. The process of claim 7, wherein the nutrient enriched organicmaterial includes ground almond shell which serves as a chelator. 10.The process of claim 7, wherein the nutrient enriched organic materialincludes ground alfalfa to facilitate water absorption.
 11. The processof claim 7, wherein the densifying step includes the step of pressingthe mixture through a die to create a pellet having a density of betweenfifty and ninety pounds per cubic foot.
 12. The process of claim 7,including the step of attaching mycorrhizal innoculum to an outersurface of the pellet.
 13. The process of claim 7, including the step ofattaching activated charcoal to an outer surface of the pellet.
 14. Theprocess of claim 7, including the step of adding an ingestion repellentto the pellet.
 15. A process for revegetating land, comprising the stepsof: performing a soil analysis on the land to be revegetated; creatingseed-bearing pellets having nutrient enriched ground organic materialaccording to the soil needs of the soil analysis; and dispersing theseed-bearing pellets over the land to be revegetatated.
 16. The processof claim 15, including the step of destroying unwanted trees orvegetation from the land to be revegetated.
 17. The process of claim 15,wherein the creating step includes the steps of: providing a mixture ofnutrient enriched ground organic material according to the soil needs ofthe soil analysis; saturating the mixture with steam; densifying themixture; cutting the densified mixture into pellets; and adhering a seedonto each pellet.
 18. The process of claim 17, wherein the nutrientenriched organic material includes ground almond shell which serves as achelator.
 19. The process of claim 17, wherein the nutrient enrichedorganic material includes ground alfalfa to facilitate water absorption.20. The process of claim 17, wherein the densifying step includes thestep of pressing the mixture through a die to create a pellet having adensity of between fifty and ninety pounds per cubic foot.
 21. Theprocess of claim 17, including the step of attaching mycorrhizalinnoculum to an outer surface of the pellet.
 22. The process of claim16, including the step of applying an herbicide to the land to berevegetated.
 23. The process of claim 22, including the step ofattaching activated charcoal to an outer surface of the pellet.
 24. Theprocess of claim 17, including the step of adding an ingestion repellentto the pellet.